Fabric Having Tobacco Entangled with Structural Fibers

ABSTRACT

A smokeless tobacco product includes smokeless tobacco and structural fibers. The structural fibers forming a network in which the smokeless tobacco is entangled. The structural fibers have a composition different from the smokeless tobacco. The tobacco-entangled fabric can have an overall oven volatiles content of at least 10 weight percent. In some embodiments, the structural fibers form a nonwoven network. In some embodiments, fibrous structures of the smokeless tobacco are entangled with the structural fibers.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of U.S. application Ser. No.14/719,763, filed May 22, 2015, which is a continuation of U.S.application Ser. No. 13/197,990, filed Aug. 4, 2011, which claimspriority to U.S. Provisional Application Ser. No. 61/371,036, filed Aug.5, 2010; U.S. Provisional Application Ser. No. 61/371,044, filed on Aug.5, 2010; and U.S. Provisional Application Ser. No. 61/452,402, filedMar. 14, 2011, each of which is wholly incorporated by reference.

TECHNICAL FIELD

This disclosure generally relates to a smokeless tobacco productincluding smokeless tobacco entangled with structural fibers to form atobacco-entangled fabric. Methods of making and using thetobacco-entangled fabric are also described.

BACKGROUND

Smokeless tobacco is tobacco that is placed in the mouth and notcombusted. There are various types of smokeless tobacco including:chewing tobacco, moist smokeless tobacco, snus, and dry snuff. Chewingtobacco is coarsely divided tobacco leaf that is typically packaged in alarge pouch-like package and used in a plug or twist. Moist smokelesstobacco is a moist, more finely divided tobacco that is provided inloose form or in pouch form and is typically packaged in round cans andused as a pinch or in a pouch placed between an adult tobacco consumer'scheek and gum. Snus is a heat treated smokeless tobacco. Dry snuff isfinely ground tobacco that is placed in the mouth or used nasally.

SUMMARY

A smokeless tobacco product is described that includes a smokelesstobacco material and structural fibers of a material having acomposition different from the smokeless tobacco. The structural fibersform a network in which the smokeless tobacco is entangled to form atobacco-entangled fabric. The tobacco-entangled fabric can have anoverall oven volatiles content of at least 10 weight percent. In someembodiments, the structural fibers form a nonwoven network. In someembodiments, fibrous structures of the smokeless tobacco are entangledwith the structural fibers. A method of preparing the smokeless tobaccoproduct is also described. The method includes bringing smokelesstobacco into contact with structural fibers and entangling the smokelesstobacco and the structural fibers to form a tobacco-entangled fabric.The tobacco-entangled fabric can have an overall oven volatiles contentof at least 10 weight percent.

A packaged smokeless tobacco product can include a container thatdefines a moisture-tight interior space and at least one piece of thetobacco-entangled fabric described herein disposed in the moisture-tightinterior space.

A method of using the smokeless tobacco product is also described. Themethod includes opening a container containing at least onetobacco-entangled fabric described herein, removing at least a piece ofthe at least one tobacco-entangled fabric, and placing the removed piecein an adult tobacco consumer's mouth. Some embodiments of a smokelesstobacco product can include a tobacco-entangled fabric in whichsmokeless tobacco is needled with fibers (e.g. cotton, polyester,viscose or the like) so that the smokeless tobacco is secured within thestructural fibers but still exposed on an exterior surface of thetobacco-entangled fabric. Further, some systems described can include aplurality of pieces of tobacco-entangled fabric packaged into acontainer where each piece has a substantially similar shape andprovides a substantially similar, predetermined portion of tobacco. Sucha system can permit an adult tobacco consumer to receive a consistentportion of tobacco (e.g., with each placement of article smokelesstobacco product in the mouth) while also experiencing the tactile andflavor benefits of having the smokeless tobacco externally exposed onthe tobacco-entangled fabric (e.g., not impeded by a pouch or pouchmaterials).

In one aspect, a system is provided. Such a system typically includes acontainer including a lid and a base that defines an interior space anda plurality of pieces of needled tobacco-entangled fabric. Each of thepieces has a substantially similar shape and a substantially similarportion of smokeless tobacco.

In some embodiments, the smokeless tobacco is exposed along at least oneexterior surface of the tobacco-entangled fabric. In certainembodiments, each of the tobacco-entangled fabric pieces includesmultiple layers of fibers. In certain embodiments, each piece oftobacco-entangled fabric includes one or more flavor strips applied toone or more exterior surfaces of each piece. In certain embodiments,each piece of tobacco-entangled fabric comprises a design embossed orstamped on one or more exterior surfaces.

The smokeless tobacco can be a dry or moist smokeless tobacco. In someembodiments, the smokeless tobacco is moist smokeless tobacco having anoven volatile content of about 30% by weight to about 61% by weight. Inother embodiments, the smokeless tobacco is a dry snuff having an ovenvolatile content of between 2% and 15%. In some embodiments, thesmokeless tobacco is a snus having an oven volatile content of between15% and 57%. In some embodiments, the tobacco-entangled fabric has anoverall oven volatile content of about 4% by weight to about 61% byweight. In certain embodiments, the structural fibers are cotton. Insome embodiments, the structural fibers are obtained from a 2.9 oz.cotton batting. In certain embodiments, the tobacco-entangled fabriccomprises multiple layers of structural fibers. In certain embodiments,the tobacco-entangled fabric comprises multiple layers of smokelesstobacco. In some embodiments, the tobacco-entangled fabric furthercomprises a backing material. A representative backing material is ascrim.

The tobacco-entangled fabric can be flavored. In some embodiments, thetobacco-entangled fabric is cut to shape. Representative shapes include,without limitation, elliptical, elongated elliptical, semi-circular,square, rectangular, elongated rectangular, rounded-edge rectangular,football-shaped, boomerang-shaped, teardrop-shaped, comma-shaped,bowtie-shaped, or peanut-shaped. In some embodiments, pieces of thetobacco-entangled fabric are embossed. In some embodiments, thetobacco-entangled fabric is perforated.

In still another aspect, a needling method of making tobacco-entangledfabric for use in the mouth is provided. Such a method typicallyincludes needling smokeless tobacco with structural fibers such that thetobacco is secured within the fibers. In some embodiments, the puncturedensity is between about 100 ppsi (penetrations per square inch) andabout 2000 ppsi (e.g., between about 400 ppsi and about 800 ppsi).

In yet another aspect, a needling method of making a tobacco-entangledfabric is provided. Such a method typically includes placing a layer ofsmokeless tobacco on a layer of backing material; placing a layer ofstructural fibers on the layer of tobacco particles; and needling thesmokeless tobacco with the structural fibers using needles that drag thestructural fibers through the tobacco's fibrous structures, therebyproducing a tobacco-entangled fabric. Such a method can further includeplacing a second layer of smokeless tobacco on the tobacco-entangledfabric; placing a second layer of structural fibers on the second layerof smokeless tobacco; and needling the second layer of smokeless tobaccowith the second layer of structural fibers and the tobacco-entangledfabric. In some embodiments, such a method can further include passingthe needled tobacco material through a nip to form the tobacco-entangledfabric.

In some embodiments, the layer of backing material is a scrim. In someembodiments, the method further includes removing the layer of backingmaterial from the tobacco-entangled fabric following the needling step.

In certain embodiments, the method further includes printing a patternon the exterior of a piece of tobacco-entangled fabric. In certainembodiments, the method further includes embossing the exterior of thetobacco-entangled fabric. In some embodiments, the method furtherincludes flavoring the structural fibers or the tobacco-entangledfabric. In certain embodiments, the method further includes cutting thetobacco-entangled fabric to shape. In some embodiments, the methodfurther includes perforating the tobacco-entangled fabric.

In another aspect, an article of manufacture is provided. Such anarticle of manufacture typically includes a cylindrical containercomprising a plurality of pieces of needled tobacco-entangled fabricsealed therein, wherein the needled tobacco-entangled fabric includessmokeless tobacco needled with structural fibers.

The products and methods described herein can also be applied to otherorally consumable plant materials in addition to smokeless tobacco. Forexample, some non-tobacco or “herbal” compositions have also beendeveloped as an alternative to smokeless tobacco compositions.Non-tobacco products may include a number of different primaryingredients, including but not limited to, tea leaves, red clover,coconut flakes, mint leaves, ginseng, apple, corn silk, grape leaf, andbasil leaf. In some embodiments, a non-tobacco product includes anon-tobacco material having fibrous structures and structural fibers ofa material having a composition different from the non-tobacco material.The structural fibers form a nonwoven network in which the fibrousstructures of the non-tobacco material are entangled to form anon-tobacco plant-entangled fabric. In some embodiments, a non-tobaccoplant-entangled fabric is made by bringing non-tobacco plant fibrousstructures into contact with structural fibers and entangling thenon-tobacco fibrous structures and the structural fibers to form anon-tobacco plant-entangled fabric. In some embodiments, a non-tobaccosmokeless product includes non-tobacco fibrous structures entangled withstructural fibers and one or more tobacco extracts. Tobacco extractsadded to a non-tobacco plant-entangled fabric can result in anon-tobacco product providing a desirable mouth feel and flavor profile.In some embodiments, the tobacco extracts can be extracted from a curedand/or fermented tobacco by mixing the cured and/or fermented tobaccowith water and removing the non-soluble tobacco material. In someembodiments, the tobacco extracts can include nicotine. In someembodiments, the non-tobacco plant-entangled fabric includes an extractof tobacco including two or more tobacco organoleptic components.

Unless otherwise defined, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which the methods and compositions of matter belong. Althoughmethods and materials similar or equivalent to those described hereincan be used in the practice or testing of the methods and compositionsof matter, suitable methods and materials are described below. Inaddition, the materials, methods, and examples are illustrative only andnot intended to be limiting. All publications, patent applications,patents, and other references mentioned herein are incorporated byreference in their entirety.

DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a packaging system including pieces oftobacco-entangled fabric.

FIG. 2A is a schematic drawing of a horizontal melt-blowing or spun bondprocess.

FIG. 2B is a schematic drawing of a vertical melt-blowing or spun bondprocess.

FIG. 2C depicts an example of an arrangement of melt-blowing spinnerets.

FIG. 3 is a schematic drawing of an exemplary method of making atobacco-entangled fabric using a melt-blowing or a spun bond process.

FIG. 4 is a schematic drawing of another exemplary method of making atobacco-entangled fabric using a melt-blowing or a spun bond process.

FIG. 5A is a schematic drawing of yet another exemplary method of makinga tobacco-entangled fabric using a melt-blowing or spun bond process.

FIG. 5B depicts an exemplary arrangement of polymer orifices, airorifices, and tobacco dispensing orifices for a melt-blowing or spunbond device that can dispense tobacco material concurrently withmelt-blowing or spun bonding structural fibers.

FIG. 6 is a schematic drawing of an exemplary method of melt-blowing orspun bonding a layer of structural fibers onto a layer of smokelesstobacco.

FIG. 7 is a schematic drawing of another exemplary method ofmelt-blowing or spun bonding a layer of structural fibers onto a layerof smokeless tobacco.

FIG. 8 is a schematic of an exemplary method of making atobacco-entangled fabric using a needle loom to intermingle smokelesstobacco with structural fibers.

FIG. 9 is a schematic showing various needles that can be used in aneedle loom.

FIG. 10 is a schematic showing an enlarged view of the needling effecton fibers.

FIG. 11 is an image of a representative embodiment of a needledtobacco-entangled fabric.

FIGS. 12A-C are micrographs showing representative tobacco-entangledfabrics formed by needling processes.

FIG. 13 is a schematic drawing of an exemplary method of making atobacco-entangled fabric by melt-blowing or spun bonding structuralfibers against smokeless tobacco and using a needle loom to interminglesmokeless tobacco with the structural fibers.

FIGS. 14A-L show exemplary various shapes into which a tobacco-entangledfabric can be cut or formed.

FIG. 15A shows a piece of tobacco-entangled fabric onto which flavorstrips have been applied. FIG. 15B shows a piece of tobacco-entangledfabric that has been wrapped or coated. FIGS. 15B and 15C showtobacco-entangled fabric pieces that have been embossed with a leafimage.

FIGS. 16A-C show representative packaging containers fortobacco-entangled fabrics.

FIG. 17 is a schematic showing an exemplary method for needling amultilayered combination of cotton structural fibers and smokelesstobacco to produce a tobacco-entangled fabric.

Like reference symbols in the various drawings indicate like elements.

DETAILED DESCRIPTION

This disclosure provides methods and materials for fabric productshaving smokeless tobacco entangled in structural fibers. The disclosureis based, in part, on the surprising discovery that entanglement ofsmokeless tobacco and structural fibers results in a smokeless tobaccoproduct that, although it has tobacco exposed along its outer surfaces,has a reduced propensity for individual smokeless tobacco particles todisperse or float in the oral cavity. The tobacco-entangled fabricremains cohesive during use, and provides a unique tactile and flavorexperience to an adult tobacco consumer. In addition, the methodsdescribed herein result in the production of tobacco-entangled fabricpieces that retain their shape and are less likely to break apart duringpackaging, handling, and shipping.

The tobacco-entangled fabric 100 can be entangling smokeless tobaccowith structural fibers using a variety of woven and nonwoventechnologies, either alone or in various combinations. Examples of thesetechnologies are sometimes referred to by the following terms:melt-blowing, spun bonding, spun laying, spun lacing, hydroentangling,spun jetting, needling, needle punching, needle felting, thermalbonding, ultrasonic bonding, radiation bonding, chemical bonding, stitchbonding, quilting, weaving, dry laying, and wet laying. Some of theseterms may overlap in meaning and/or include some of the same processingsteps. Moreover, certain of these terms may sometimes be usedinterchangeably. Moreover, these processes can be used either alone orin various combinations to provide a desired entanglement of smokelesstobacco with structural fibers. As used herein, the term “structuralfibers” refers to fibers that provide a network for retaining smokelesstobacco and enable the tobacco-entangled fabric to be cohesive whenhandled or placed within an adult tobacco consumer's mouth. Thestructural fibers can be entangled with fibrous structures of thesmokeless tobacco such that the tobacco's fibrous structures wrap atleast partially around one or more structural fibers.

In some embodiments, smokeless tobacco is placed adjacent structuralfibers and then mechanically entangled with the structural fibers (e.g.,by needling, needle punching, needle felting, spun lacing, orhydroentangling). In other embodiments, smokeless tobacco is mixed intostructural fibers during processing steps of the structural fibers(e.g., during dry laying or wet laying process) or mixed into a streamof polymeric structural fibers as they are being spun (e.g., during amelt-blowing, spun bonding, or spun laying process). In some of theseprocesses, the smokeless tobacco and the structural fibers may becomesufficiently entangled to provide a tobacco-entangled fabric. However,additional processing techniques, such as needling, needle punching,needle felting, thermal bonding, ultrasonic bonding, radiation bonding,chemical bonding, stitch bonding, and/or quilting, may be used tofurther entangle or lock the smokeless tobacco into a network of thestructural fibers. The resulting tobacco-entangled fabric can then befurther processed and packaged as a number of different smokelesstobacco products. Although other methods of producing thetobacco-entangled fabric are also contemplated, various methods arediscussed in more detail below.

In some embodiments, the structural fibers provide a nonwoven networkfor retaining the smokeless tobacco. As used herein, the term “nonwoven”means a material made from fibers that are connected by entanglementand/or bonded together by a chemical, heat or solvent treatment wherethe material does not exhibit the regular patterns of a woven or knittedfabric. In some embodiments, the structural fibers material areinitially provided as a woven fabric (e.g., a loosely woven cottonfabric), but manipulated by entangling the smokeless tobacco such thatthe resulting tobacco-entangled fabric constitutes a nonwoven networkdue to a loss of order of the fibers.

The structural fibers 110 can be arranged such that thetobacco-entangled fabric is dimensionally stable. As used herein,“dimensionally stable” means that the fabric retains its shape under itsown weight. In some embodiments, a piece of the tobacco-entangled fabricis flexible, yet can be picked up at one end without the force ofgravity causing the piece to bend or sag.

Structural fibers can be natural fibers and/or synthetic fibers, whichcan be processed and/or produced using a variety of techniques,including some of the techniques discussed above. Although thestructural fibers are not intended to provide tobacco components,certain structural fibers can absorb and desorb certain tobaccocomponents when combined with the smokeless tobacco. Structural fibers,however, can also be coated with flavorants or other additives. In someembodiments, the structural fibers can modify the release of flavorantsto provide a desired flavor release rate. In some embodiments, thestructural fibers are reconstituted cellulosic fibers formed fromtobacco plant tissue. In still other embodiments, structural fibers caninclude milled tobacco at least partially embedded into the structuralfibers.

Exemplary Packaging System

Referring to FIG. 1, some embodiments of a smokeless tobacco system 50can include one or more pieces of tobacco-entangled fabric 100 ofstructural fibers entangled with fibrous structures of smokeless tobacco105. A plurality of pieces of tobacco-entangled fabric 100 can bearranged in an interior space 51 of a container 52 that mates with a lid54. The interior space 51 can be moisture tight to prevent thetobacco-entangled fabric from drying out. The plurality of the articles100 arranged in the container 52 can all have a substantially similarshape so that an adult tobacco consumer can conveniently select any ofthe similarly shaped tobacco-entangled fabric 100 therein for use in themouth and receive a generally consistent portion of the smokelesstobacco 105. In other embodiments, the container 52 can include a stripof tobacco-entangled fabric and pieces of tobacco-entangled fabric canbe separated from the strip and placed in an adult tobacco consumer'smouth for use in the mouth. In still other embodiments, thetobacco-entangled fabric can be incorporated into other types ofsmokeless tobacco products. Some embodiments of the tobacco-entangledfabric 100 can include a smokeless tobacco 105 homogeneously distributedthroughout the network of the structural fibers 110. In otherembodiments, the tobacco-entangled fabric 100 can include regions havingdifferent amounts of smokeless tobacco. For example, thetobacco-entangled fabric 100 can be a layered product having one or morelayers primarily composed of structural fibers 110 and one or morelayers primarily composed of smokeless tobacco 105, but with fibers fromadjacent layers being entangled to form a cohesive tobacco-entangledfabric.

The container 52 and lid 54 can releasably mate at a connection rim 53so as to maintain freshness and other product qualities of thetobacco-entangled fabric 100 contained therein. Such qualities mayrelate to, without limitation, texture, flavor, color, aroma, mouthfeel, taste, ease of use, and combinations thereof. In some embodiments,the container is moisture-tight. Certain containers can be air-tight. Inparticular, the container 52 may have a generally cylindrical shape andinclude a base and a cylindrical side wall that at least partiallydefines the interior space 53. The connection rim 53 formed on thecontainer 52 provides a snap-fit engagement with the lid 54. It will beunderstood from the description herein that, in addition to thecontainer 52, many other packaging options are available to holdtobacco-entangled fabric 100.

Method of Using the Tobacco-Entangled Fabric

In certain embodiments, each piece of tobacco-entangled fabric 100 canbe configured for use in the mouth in a manner similar to that of anindividual pouch containing smokeless tobacco therein. Unlike thetypical individual pouch products, however, in which the paper orpaper-like pouch material is in contact with the adult tobaccoconsumer's cheek and gum, the tobacco-entangled fabric 100 describedherein can provide a desired tactile feel in an adult tobacco consumer'smouth. For example, the combination of the structural fibers andsmokeless tobacco (including the tobacco's fibrous structures) canprovide a softer mouth feel. Moreover, in certain embodiments, thestructural fibers can be elastic or pliable (e.g., a polymericpolyurethane such as DESMOPAN DP 9370A available from Bayer) thusforming a tobacco-entangled fabric that can tolerate being “worked” inthe mouth. For example, the tobacco-entangled fabric 100 can be workedto provide flavor and/or to comfortably conform between the cheek andgum. Furthermore, tobacco-entangled fabric 100 can provide direct tissuecontact with some of the smokeless tobacco. Additionally, a piece oftobacco-entangled fabric remains cohesive and thus reduces the instancesof substantial pieces of smokeless tobacco floating to an undesiredlocation and/or position in the adult tobacco consumer's mouth. In someembodiments, combinations of mouth-stable and mouth-dissolvable fibersare combined with the smokeless tobacco to provide a product thatbecomes looser when placed in an adult tobacco consumer's mouth, yetremains cohesive. The structural fibers can also be a composite ofmultiple materials, which may include both mouth-stable andmouth-dissolvable materials.

Briefly, in use, the system 50 can be configured so that an adulttobacco consumer can readily grasp at least one piece of thetobacco-entangled fabric 100 for placement in the adult tobaccoconsumer's mouth, thereby receiving a predetermined portion of smokelesstobacco with each tobacco-entangled fabric 100. In some embodiments, thepredetermined portion of smokeless tobacco is generally consistent witheach piece of the tobacco-entangled fabric 100 stored in the container.For example, each piece can provide between 0.25 and 4.0 grams ofsmokeless tobacco. Accordingly, the system 50 can permit an adulttobacco consumer to receive consistent portions of smokeless tobaccowith each delivery (e.g., placement of the piece of tobacco-entangledfabric 100 in the mouth). In some embodiments, an exterior surfaceincludes a combination of structural fibers 110 and smokeless tobacco105 to provide a unique tactile and flavor experience.

The container 52 and lid 54 can be separated from one another so thatthe adult tobacco consumer can have access to the one or more pieces oftobacco-entangled fabric 100 contained therein. Thereafter, the adulttobacco consumer can obtain a predetermined portion of smokeless tobacco105 by readily grasping any one of the pieces of tobacco-entangledfabric 100 (e.g., without the need to estimate an amount of thesmokeless tobacco) and can place the piece of tobacco-entangled fabric100 in his or her mouth. The remaining pieces of the tobacco-entangledfabric 100 can be enclosed in the container 52 when the lid 54 isreengaged with the container 52. During use, the network of structuralfibers can remain cohesive and thus reduce the likelihood of substantialportions of smokeless tobacco breaking away from the tobacco-entangledfabric and “floating” in the adult tobacco consumer's mouth. After theadult tobacco consumer has enjoyed the piece of tobacco-entangled fabric100, the adult tobacco consumer can remove the tobacco-entangled fabric100 from his or her mouth and discard it. In some embodiments, thecontainer 52 has an additional receptacle for receiving used pieces oftobacco-entangled fabric.

Methods of Producing the Tobacco-Entangled Fabric

The structural fibers can be provided, processed, and/or produced usinga number of methods. In some embodiments, the structural fibers materialis initially provided as a fabric (either woven or nonwoven). In otherembodiments, natural structural fibers can be obtained in raw form(e.g., cotton in bales) and processed to produce a non-cohesive web,which can be further processed to produce the cohesive tobacco-entangledfabric. In other embodiments, synthetic fibers can be purchased or spunin separate operations and then processed or manipulated to form afabric and to entangle smokeless tobacco. Moreover, smokeless tobaccomay be mixed with the structural fibers during any point in the variousprocesses of processing, producing, and/or further manipulating thestructural fibers to produce the tobacco-entangled fabric. As will bediscussed below, various entangling and/or bonding techniques can beused to secure the structural fibers together such that the network ofstructural fibers retains the smokeless tobacco. Although variousmethods for creating a tobacco-entangled fabric 100 are describedherein, other methods are also contemplated.

Processing of Preformed Structural Fibers

A tobacco-entangled fabric 100 can include preformed structural fibers.In some embodiments, preformed structural fibers (either natural orsynthetic fiber) are dry laid or wet laid to provide an initial web ofstructural fibers. Synthetic fibers can be spun in a separate process orobtained from a merchant. This web of structural fiber can be cohesiveor non-cohesive. In some embodiments, smokeless tobacco is mixed withthe structural fibers during these processes. In other embodiments,smokeless tobacco can be mixed and entangled with a web of structuralfibers after the web is produced.

Dry Laid Nonwoven Systems

A dry laid system can arrange preformed structural fibers into a web.The preformed structural fibers can be between 1.2 and 100 cm long. Forexample, the preformed structural fibers can be cotton. Natural cottonmay be shipped to a manufacturing location in the form of bales. In someembodiments, smokeless tobacco can be mixed in with the structuralfibers during bale processing, just prior to input into a web formingapparatus, or entangled with the structural fibers after the formationof the web of the preformed fibers using, for example, a needlingprocess.

During a dry laid process, preformed fibers (e.g., cotton) can bemechanically and/or pneumatically processed from a bale to a point wherethe fibers can be introduced into a web-forming machine. A dry laidprocess can include the following steps: bale opening; blending; coarseopening; fine opening; and web-form feeding. During these processes,pins can be used to open fiber tufts in preparation for forming a web.Rolls can also reduce the tuft size by using the principle of cardingpoints between the different rolls The opened fiber with the reducedtufts can be transferred via an air stream to a web-former. In someembodiments, smokeless tobacco is mixed with the opened fibers justbefore being fed into a web-former.

One dry laid method of forming a nonwoven web is carding. The cardingprocess separates small tufts into individual fibers, begins toparallelize the fibers, and forms the fibers into a web. In the cardingprocess, fibers are held by one surface while another surface combs thefibers causing individual fiber separation. A large rotating metalliccylinder covered with card clothing can be used to card preformedfibers. The card clothing can include needles, wires, or fine metallicteeth embedded in a heavy cloth or in a metallic foundation. The top ofthe cylinder may be covered by alternating rollers and stripper rolls ina roller-top card. The fibers, optionally mixed with smokeless tobacco,can be fed by a chute or hopper and condensed into the form of a lap orbatting. Needles of the two opposing surfaces of the cylinder and flatsor the rollers can be inclined in opposite directions and move atdifferent speeds. The fibers are aligned in the machine direction andform a coherent web below the surface of the needles of the maincylinder. The web can be removed from the surface of cylinder anddeposited on a moving belt.

Another dry laid method of forming a nonwoven web is garnetts. Garnettsuses a group of rolls placed in an order that allows a given wireconfiguration, along with certain speed relationships, to level,transport, comb and interlock fibers to a degree that a web is formed.Garnetts can deliver a more random web than carding.

An air-stream can also be used to orient the structural fibers in acarding or garnetts system. For example, starting with a lap or pliedcard webs fed by a feed roller, the fibers can be separated by alicker-in or spiked roller and introduced into an air-stream. Theair-stream can randomize the fibers as they are collected on thecondenser screen. The web can be delivered to a conveyor fortransporting to a bonding area. In some embodiments, the length offibers used in air-laying varies from 2 to 6 cm. In some embodiments,the air-stream also delivers a stream of smokeless tobacco to be mixedwith the nonwoven fibers.

A centrifugal system can also be used to form a nonwoven web by throwingoff fibers from the cylinder onto a doffer with fiber inertia, which issubject to centrifugal force. Orientation in the web isthree-dimensional and is random or isotropic. In some embodiments,smokeless tobacco is added to the centrifugal system to be mixed withthe structural fibers.

Web formations can be made into the desired web structure by thelayering of the webs from either the card and/or garnetts. Layeringtechniques include longitudinal layering, cross layering, andperpendicular layering. In some embodiments, layers of smokeless tobaccoare deposited between layers of carded or garneted preformed fibers. Aswill be discussed below, the nonwoven fabric can be further processed toentangle or interlock the preformed structural fibers of the web witheach other and/or with smokeless tobacco. These processed includeneedling, needle punching, needle felting, stitch bonding, thermalbonding, ultrasonic bonding, radiation bonding, chemical bonding,air-jet entanglement, spun lace, and hydroentanglement.

Wet Laid Nonwoven Systems

In a wet laid web process, structural fibers are dispersed in an aqueousmedium. Specialized paper machines can be used to separate the waterfrom the fibers to form a uniform sheet of material, which is thenbonded and dried. Wet laid Nonwoven Systems can have high productionrate (up to 1000 m/min) and the ability to blend a variety of fibersfrom papermaking technology. Any natural or synthetic fiber could beused in the production of wet-laid nonwovens. For example, cottonlinters, wood pulp, and cellulose structural fibers can be used inwet-laid process. Synthetic fibers (e.g., rayon, polyester) can be usedand can provide thermobonding capabilities. Crimped fibers can make avery soft and bulky tobacco-entangled fabric. In some embodiments, thefibers are between 2 mm and 50 mm long. The wet-laid nonwoven system canuse consistencies of between 0.005% and 0.05%. In some embodiments,smokeless tobacco is also suspended in the water with structural fibers.

After swelling and dispersion of the fibers in water, the mixing vatscan be transported to the head box from where they are fed continuouslyinto a web-laying machine. In some embodiments, smokeless tobacco isalso added to the mixing vats prior to feeding the dispersion to theweb-laying machine. The smokeless tobacco can be treated prior to addingthem to the dispersion to retain moisture and flavors during thesubsequent processing steps. For example, the smokeless tobacco can beencapsulated. In other embodiments, soluble tobacco components (e.g.,flavorants) can be removed from the smokeless tobacco before adding thesmokeless tobacco to the vat and can be added back to the smokelesstobacco after the wet laid process. Squeezing machines can be used todehydrate the web. The web can then be dried and bonded. For example,convection, contact and radiation dryers can be used to both dry andbond the web.

Bonding agents can be added to the wet laid material to help bond thestructure. For example, meltable fibers can also be used or added to theweb for bonding and activated by a heating step either during drying, orduring a later hot calendaring step. Examples of fibers of this typeinclude vinyon, polypropylene, cellulose acetate, and special lowmelting polyester or polyamide copolymers. In other embodiments, beadsof globules of meltable materials can be added during the dry laidprocess and activated by a heating step to result in spot bonding.

Other in-line treatments can include aperturing and water-jetentanglement. Apertures are regularly spaced holes, and can be selectedfor aesthetics or for performance (e.g., improving permeability toincrease access to the smokeless tobacco throughout tobacco-entangledfabric when placed in an adult tobacco consumer's mouth). One method ofaperturing uses a course forming wire, so that the sheet is formedaround the protruding “knuckles” in a regular pattern. Another methoduses high-pressure water showers and patterned cylinders to rearrangethe fiber into the desired pattern, which can be used to entangle thefibers and/or create apertures. A process sometimes known as spun lacecan use precise jets of high pressure water to hydroentangle thestructural fibers with each other and/or with smokeless tobacco. Priorto hydroentanglement, soluble tobacco components can be removed from thesmokeless tobacco and can be added back to the smokeless tobacco afterthe hydroentanglement process. Other processes, including thosediscussed below, can also be used with a web laid web to entanglesmokeless tobacco and/or to bond the structural fibers such that thetobacco-entangled fabric is cohesive.

Production of Webs of Polymeric Structural Fibers

Polymer-based systems for producing polymeric structural fibers having anonwoven structure include, for example, melt-blown systems and spunbond systems. Other systems for producing polymeric fibers includeelectro spinning and force spinning. Moreover, other systems forproducing polymeric structural fibers are also contemplated.

Both melt-blowing and spun bonding processes extrude polymeric materialsand attenuate (stretch) the extruded polymer to produce fibers.Referring to FIGS. 2A and 2B, the extruded and attenuated fibers can becollected on a vacuum drum 212 or a conveyor 214. Also as shown in FIGS.2A and 2B, these processes can be run in both a horizontal and avertical orientation. Spun bond or melt-blown structural fibers 110 canthen be collected on a wind up reel 240 for later entangling withsmokeless tobacco. In other embodiments, such as those depicted in FIGS.3, 4, 5A, 5B, 6, 7, and 13, smokeless tobacco 105 can be placed incontact with and/or entangled with the spun bond or melt-blownstructural fibers 110 during the spun bond or melt-blowing processes. Insome embodiments, milled tobacco is added to the polymeric materialbefore it is melt-blown or spun bond such that the resulting melt-blownor spun bond fibers include milled tobacco at least partiallyencapsulated by the polymeric material of the structural fibers.

The spun bond and melt-blown processes are somewhat similar from anequipment and operator's point of view and smokeless tobacco can beadded to these processes in substantially similar manners. The two majordifferences between a typical melt-blown process and a typical spun bondprocess are: i) temperature and volume of the air used to attenuate thefilaments; and ii) the location where the filament draw or attenuationforce is applied. A melt-blown process uses relatively large amounts ofhigh-temperature air to attenuate the filaments. The air temperature canbe equal to or slightly greater than the melt temperature of thepolymer. In contrast, the spun bond process generally uses a smallervolume of air close to ambient temperature to first quench the fibersand then to attenuate the fibers. In the melt-blown process, the draw orattenuation force is applied at the die tip while the polymer is stillin the molten state. Application of the force at this point can formmicrofibers but does not allow for polymer orientation. In the spun bondprocess, this force is applied at some distance from the die orspinneret, after the polymer has been cooled and solidified. Applicationof the force at this point provides the conditions necessary for polymerorientation, but is not conducive to forming microfibers.

FIG. 2C depicts an exemplary arrangement of polymer orifices and airorifices for a melt-blowing apparatus. Air orifices 124 can be adjacentto the polymer orifices 122. As shown in FIG. 2C, the air orifices 124may surround each polymer orifice 122. Each combination of a polymerorifice 122 with surrounding air orifices 124 is called a spinneret 129.For example, the melt-blowing device 120 can have between 10 and 500spinnerets 129 per square inch. The polymer orifices 122 and the gasvelocity through gas orifices 124 can be combined to form fibers of 100microns or less. In some embodiments, the melt-blown fibers have anaverage diameter of 30 microns or less. In particular embodiments, themelt-blown fibers have an average diameter of between 0.5 and 5 microns.In some embodiments, the spinnerets 129 each have a polymer orificediameter of less than 900 microns. In some embodiments, the spinnerets129 each have a polymer orifice diameter of at least 75 microns. Theaverage polymer orifice diameter can range from 75 microns to 900microns. In particular embodiments, the average polymer orifice diametercan be between 150 microns and 400 microns. In certain embodiments,polymer orifice diameters of about 180 microns, about 230 microns, about280 microns, or about 380 microns are used.

The processes of extruding, attenuating, and depositing the polymericfibers can result in some bonding between the different fibers. Theamount of bonding can depend on a host of variables, including thetemperature of the polymer and the attenuating air. Accordingly,melt-blown processes generally result in more bonding between fibersthan spun bond process. Accordingly, additional bonding and/ormechanical interlocking processes can be applied to melt-blown or spunbond polymer fibers to further ensure that the tobacco-entangled fabricremains cohesive when placed in an adult tobacco consumer's mouth.

Smokeless tobacco 105 can be combined with melt-blown and/or spun bondfibers using a number of methods. In some embodiments, smokeless tobaccoare introduced directly into the high velocity fiber stream 230 ofeither a melt-blown or spun bond process. For example, the high velocityfiber streams can also be angled towards a free falling flow ofsmokeless tobacco. For example, referring now to FIG. 3, loose smokelesstobacco 105 can be directed to fall into the high velocity fiber streams230 a and 230 b. As the tobacco falls into the streams 230 a and 230 b,the tobacco's fibrous structures become entangled with the melt-blown orspun bond structural fibers. In some embodiments, the structural fibers110 are melt-blown at a sufficiently high temperature to result insufficient bonding between the structural fibers such that thetobacco-entangled fabric 100 becomes cohesive and dimensionally stable.In other embodiments, not shown, the mixture of melt-blown or spun bondstructural fibers and smokeless tobacco can be heated on the conveyor(e.g., by IR lamp) to bond the structural fibers. A cutting apparatus350 can be used to cut the tobacco-entangled fabric 100 to desireddimensions. In some embodiments, extruders 120 a and 120 b each deliverdifferent structural fibers 110, both in terms of materials, dimensions,or even processes. For example, in some embodiments, a tobacco-entangledfabric can include both melt-blown and spun-bond fibers. In someembodiments, a tobacco-entangled fabric includes a combination ofmouth-stable structural fibers and mouth-dissolvable fibers using amelt-blowing or spun bonding process.

Mouth-stable structural fibers can include the full array of extrudablepolymers, such as polypropylene, polyethylene, PVC, viscose, polyester,and PLA. In some embodiments, the mouth-stable structural fibers havelow extractables, have FDA food contact approval, and/or be manufacturedby supplies who are GMP approved. Highly desirable are materials thatare easy to process and relatively easy to approve for oral use (e.g.quality, low extractables, has FDA food contact approval, suppliers areGMP approved). Mouth-stable structural fibers can also include naturalfibers, such as cotton or viscose (solvent cast).

Mouth-dissolvable fibers could be made from hydroxypropyl cellulose(HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH),PVP, polyethylene oxide (PEO), starch and others. These fibers couldcontain flavors, sweeteners, milled tobacco and other functionalingredients. The fibers could be formed by extrusion or by solventprocesses.

Referring now to FIG. 4, smokeless tobacco material 105 can be blown bya blower 418 into a stream 230 of melt-blown or spun bond structuralfibers 110 exiting a die in a horizontal process. The stream ofsmokeless tobacco 105 entangled with the structural fiber 110 can becollected and calendared between a pair of vacuum drums 212 a and 212 b.Calendaring can be used in combination with heat (either added orlatent) to bond the structural fibers. In other embodiments, additionalmethods of bonding or entangling the structural fibers 110 can be usedon the tobacco-entangled fabric 100.

Referring now to FIGS. 5A and 5B, tobacco can also be deposited betweenadjacent spinnerets 129 by the same apparatus producing the structuralfibers. As shown, a melt-blowing device 120′ can be configured todeliver smokeless tobacco 105 during a melt-blowing process. In additionto including a polymer extruder 121, the melt-blowing device 120′ alsoincludes a tobacco conveyor 125 that delivers smokeless tobacco 105 tobe mixed with the melt-blown polymeric structural fibers 110 as thepolymeric material exits the polymer orifices 122. As shown in FIG. 5B,tobacco delivering orifices 126 may be placed adjacent polymer orifices122 and air orifices 124. FIG. 5B, like the other figures, is not toscale. In practice the smokeless tobacco delivering orifices 126 may beone to several orders of magnitude larger than the polymer orifices 122.In other embodiments, tobacco delivering orifices 126 may be in rowsbetween one or more rows of spinnerets 129. The precise dimensions andarrangement of the smokeless tobacco delivering orifices 126 will dependon the properties of the particular smokeless tobacco and the selectedmethod of delivery. In some embodiments, the smokeless tobacco 105 maybe conveyed through the melt-blowing device 120′ pneumatically in orderto prevent clogging. In other embodiments, vibrating conveyors may beused. The combination of the smokeless tobacco 105 and the polymericstructural fibers 110 can be deposited onto a conveyor belt 11 to form ahomogeneous tobacco-entangled fabric 100. The speed of the conveyor belt11 can be controlled to build a desired thickness (for example ofbetween 0.1 and 1.0 inches). The homogeneous tobacco-entangled fabric100 may then be die cut.

Smokeless tobacco can also be deposited onto a vacuum drum or conveyorand covering with fibers from the fiber stream to contact the smokelesstobacco with structural fibers. In some embodiments, covering thesmokeless tobacco with melt-blown or spun bond fibers results in atleast some entangling of the tobacco's fibrous structures and themelt-blown or spun bond fibers. Referring now to FIGS. 6 and 7,smokeless tobacco 105 (e.g., smokeless tobacco material) may bedeposited onto a carrier 111 or web 132 and transported past amelt-blowing device 120 to deposit melt-blown polymeric fibers 110 ontothe smokeless tobacco material 105. In particular embodiments, thesmokeless tobacco 105 is compacted (e.g., subjected to a mechanicalcompacting process) prior to passing under spinnerets 129. The carrier11 or 132 is supported by a platform 7 during the melt-blowing and/orspun bond processes. In some embodiments, the platform produces a vacuumin the area underneath the position of the spinnerets 129. The vacuumcan pull the melt-blown polymeric fibers towards the platform 7 and mayassist in fiber bonding. Porous layers (porous carrier 11, porous web132, porous layers of tobacco material 105, etc.) can permit the vacuumto pull the melt-blown polymeric fibers towards platform 7. In certainembodiments, an air stream for disrupting tobacco material can bepositioned immediately prior to the vacuum section of platform 7, whichcan result in intermingling of the tobacco's fibrous structures with thestructural fibers.

FIGS. 6 and 7 depict conveyors 12 that compact the deposited smokelesstobacco 105. The smokeless tobacco 105 can be pre-compressed to adesired thickness and density prior to melt-blowing the polymeric fiber110. For example, the thickness of a compacted layer of smokelesstobacco prior to application of the melt-blown polymeric fiber can bebetween 1 mm and 5 mm, of between 3 mm and 10 mm, of between 0.5 cm and2 cm, of between 1 cm and 3 cm. A polymeric fiber layer deposited overthe compacted layer of smokeless tobacco can have a thickness of between10 microns and 100 microns, of between 50 microns and 500 microns, ofbetween 100 microns and 1000 microns, of between 0.5 mm and 5 mm, or ofbetween 1 mm and 10 mm. For example, multiple layers of smokelesstobacco and multiple layers of melt-blown or spun bond structural fiberscan be deposited in an alternating fashion.

In other embodiments, not depicted, the smokeless tobacco 105 isdeposited in a loose form and not compacted prior to depositing thepolymeric fibers 110. For example, a non-compacted layer of smokelesstobacco can be deposited on a conveyor and have a thickness of between,for example, 0.1 inches and 3.0 inches. In some embodiments, multiplelayers of non-compacted smokeless tobacco of between 0.1 and 1.0 inchesthickness are successively deposited along with alternating layers ofpolymeric fiber, each layer of melt-blown polymeric fiber having athickness of between 10 and 100 microns, of between 50 microns and 500microns, of between 100 microns and 1000 microns, of between 0.5 mm and5 mm, or of between 1 mm and 10 mm. In some embodiments, the layers ofpolymeric fiber alternate between melt-blown fibers and spun bondfibers. The tobacco-entangled fabric 100 can be cut width-wise,length-wise, and thickness-wise to form a piece of tobacco-entangledfabric 100 having the desired dimensions. For example, a piece oftobacco-entangled fabric having a dimensions of 1 inch×1 inch×0.1 inchmay be made by (a) forming a 0.1 inch thick tobacco-entangled fabric andcutting out a one inch square; or (b) by forming a 1 inch thicktobacco-entangled fabric and slicing off pieces every 0.1 inch. The cutsurfaces can have a different surface texture than non-cut surfaces.

In some circumstances, as shown in FIG. 6, a carrier 111 may include abacking layer that does not contribute fibers to the finaltobacco-entangled fabric 100 and can be readily peeled away or removedafter the melt-blowing or spun bond process is completed. In someembodiments, the smokeless tobacco/melt-blown or spun bond polymericfiber composite is further processed to further secure the smokelesstobacco to the melt-blown polymeric fiber. For example, the smokelesstobacco/melt-blown polymeric fiber composite may be needled, needlepunched, needle felted, air-jet entangled, spun laced, orhydroentangled.

Multiple layers of tobacco material 105 and polymeric fiber 110 can bebuilt up to a desired thickness. For example, the melt-blowntobacco-entangled fabric can have a thickness of between 0.1 and 1.0inches. Accordingly, in some embodiments, multiple melt-blowing or spunbonding devices 120 and/or smokeless tobacco dispensers are alternatedin series over a conveyor system to deposit alternating layers ofmelt-blown polymeric fibers and smokeless tobacco. By controlling thespeed of the conveyor system and the rates of depositing melt-blown orspun bond polymeric fiber and smokeless tobacco, the thickness of eachlayer can be controlled to have thicknesses in the ranges discussedabove. In some embodiments, the thickness of each layer is sufficientlythin such that each melt-blown polymeric fiber layer contacts adjacentstructural fiber layers and results in the tobacco's fibrous structuresbeing entangled within a nonwoven network of structural fibers. Thepolymeric fibers of each layer can then be bonded to form a solidtobacco-entangled fabric 100 having bonding between adjacent structuralfiber layers. In other embodiments, the concentration of smokelesstobacco can vary between different layers of melt-blown polymer. Forexample, interior layers may have a lower concentration of smokelesstobacco. In certain embodiments, a layer or deposit of smokeless tobaccocan be disrupted during or immediately prior to passing under a stream230 of polymeric structural fibers to distribute the tobacco materialthroughout the polymeric structural fibers. For example, air jets can bepositioned underneath the carrier 11 or web 132 to project at least someof the smokeless tobacco into a “waterfall” of the polymeric fiberleaving the spinnerets 129.

Melt-Blowing Fiber Properties

Melt-blown webs usually have a wide range of product characteristics.Melt-blown webs can have a random fiber orientation; a low to moderateweb strength, deriving strength from mechanical entanglement andfrictional forces; a fiber diameter ranges from 0.1 to 100 microns; abasis weight ranges from 1-350 g/m²; and have a smooth surface textureand a circular cross-section. In some embodiments, the melt-blown fiberscan have a diameter range of between 0.5 and 5 microns. The fiberlengths in a melt-blown web can be variable; it can be produced in therange from a few millimeters to several hundred centimeters in lengthand usually exists over a broad range. The fiber cross-section is alsovariable, ranging from circular to a flat configuration and othervariations.

Composite formation can be used to provide enhancement of otherproperties. For example, an SMS structures based on a three-ply systemof Spun bond/Melt-blown/Spun bond plies can be used in combination withsmokeless tobacco to provide an enhanced composite tobacco-entangledfabric. Melt-blowing processes can also be used to produce compositefibers, which include multiple materials. Electro spun and force spunfibers, as discussed below, can also be added for texture.

Spun Bond Fiber Properties

The spinning process is similar to the production of continuous filamentyarns and utilizes similar extruder conditions for a given polymer.Accordingly, spun bond fibers have at least a partial orientation. Apartial orientation can increase strength and decrease extensibility.Spun bonded webs offer a wide range of product characteristics rangingfrom very light and flexible structure to heavy and stiff structure. Theproperties include: random fibrous structure; most spun bond webs arelayered or shingled structure, the number of layers increases withincreasing basis weight; basis weights range between 5 and 800 g/m²,typically 10-200 g/m²; fiber diameters range between 1 and 50 μm; webthicknesses range between 0.1 and 4.0 mm, typically 0.2-1.5 mm; highstrength-to-weight ratios compared to other nonwoven, woven, and knittedstructures; high tear strength (for area bonded webs only); planarisotropic properties due to random lay-down of the fibers; good fray andcrease resistance; high liquid retention capacity due to high voidcontent; high in-plane shear resistance, and low drapeability.

Electro Spinning Systems

Electro spinning is a process that spins fibers of diameters rangingfrom 10 nm to several hundred nanometers; typically polymers aredissolved in water or organic solvents. The process makes use ofelectrostatic and mechanical force to spin fibers from the tip of a fineorifice or spinneret. The spinneret is maintained at positive ornegative charge by a DC power supply. When the electrostatic repellingforce overcomes the surface tension force of the polymer solution, theliquid spills out of the spinneret and forms an extremely finecontinuous filament. These filaments are collected onto a rotating orstationary collector with an electrode beneath of the opposite charge tothat of the spinneret where they accumulate and bond together to formnanofiber fabric. Electro spun nanofibers, in some embodiments, can beadapted to dissolve in the mouth. For example, fibers can be spun fromwater (or other solvent) solutions of soluble polymers such as HPC,HPMC, or PVOH; these fibers could contain flavors, sweeteners, milledtobacco or other functional ingredients. For example, the bulk of thetobacco-entangled fabric can be made of one or multiple melt-blownlayers designed from coarse to fine filaments and combined with electrospun nanofiber web. Melt-blown and/or spun bond layers can providestability while an outer electro spun nanofiber layer can improvesmoothness. In some embodiments, electro spun fibers are layered withnatural structural fibers (e.g., cotton fibers) and/or polymericstructural fibers to provide a textural sensation. In some embodiments,electro spun fibers are chopped and mixed with polymeric structuralfibers (e.g., melt-blown or spun bond fibers) and thermally bondedwithin the network of structural fibers to provide a unique texturalsensation.

Force Spinning Systems

Force spinning is a process that spins fibers of diameters ranging from10 nm to 500 nm using a rotary drum and a nozzle, much like a cottoncandy machine. The process makes use of a combination of hydrostatic andcentrifugal pressure to spin fibers from the nozzle. For example, onetype of force spinning is rotary jet spinning, where a polymericmaterial is retained inside a reservoir atop a controllable motor andextruded out of a rapidly rotating nozzle. Force spun nanofibers, insome embodiments, can be adapted to dissolve in the mouth. For example,fibers can be force spun from water (or other solvent) solutions ofsoluble polymers such as HPC, HPMC, or PVOH; these fibers could containflavors, sweeteners, milled tobacco or other functional ingredients. Thebulk of the tobacco-entangled fabric can be made of one or multiplemelt-blown layers designed from coarse to fine filaments and combinedwith force spun nanofiber web. Melt-blown and/or spun bond layers canprovide stability while an outer force spun nanofiber layer can improvesmoothness. In some embodiments, force spun fibers are layered withnatural structural fibers (e.g., cotton fibers) and/or polymericstructural fibers to provide a textural sensation. In some embodiments,force spun fibers are chopped and mixed with polymeric structural fibers(e.g., melt-blown or spun bond fibers) and thermally bonded within thenetwork of structural fibers to provide a unique textural sensation.

Stabilizing—Mechanical Entanglement and/or Bonding

After the smokeless tobacco and structural fibers are arranged, eitherin layers or intermingled, the web may need further mechanical, thermal,or chemical treatment in order to have the structural fibers form anetwork in which fibrous structures of the tobacco material areentangled. In other embodiments, a tobacco-entangled fabric may befurther processed (e.g., entangled or bonded) to produce a more cohesiveand/or dimensionally stable tobacco-entangled fabric. For example,mixing smokeless tobacco in with cotton fibers in a carding process mayresult in an intermingled web of structural fibers and smokelesstobacco, but the carding process may not sufficiently entangle thefibers such that the web is cohesive. Likewise, a spun bond processdepositing polymeric fibers on a layer of smokeless tobacco does bringthe polymeric structural fibers in contact with smokeless tobacco, butmay not result in an intermingling of the polymeric structural fiberswith the smokeless tobacco. Moreover, tobacco material and a web ofstructural fibers can be combined and entangled by needling, needlepunching, needle felting, air-jet entangling, spun lacing, and/orhydroentanglement processes. Accordingly, a web including smokelesstobacco can be subject to needling, needle punching, needle felting,air-jet entangling, spun lacing, hydroentanglement, stitch bonding,thermal bonding, ultrasonic bonding, radiation bonding, chemicalbonding, combinations thereof, or other treatment steps to make thetobacco-entangled fabric cohesive and/or dimensionally stable.

Needling Processes

Some embodiments of the tobacco-entangled fabric 100 can includesmokeless tobacco 105 that is needled with the structural fibers 110 sothat the smokeless tobacco is entangled, and thereby secured, within thestructural fibers of a tobacco-entangled fabric 100. The structuralfibers can be provided by one of the methods discussed above (with orwithout the inclusion of smokeless tobacco intermingled in thestructural fibers). In certain embodiments, one or both exteriorsurfaces of a needled tobacco-entangled fabric can be predominantlysmokeless tobacco (including fibrous structures) or predominantlystructural fibers.

Needling, also known as needle punching, is a process by which a fabricis mechanically formed by penetrating a web of fibers with an array ofbarbed needles that carry tufts of the fibers in a vertical direction.Needle felting is a similar process. Referring now to FIGS. 8-10, thesmokeless tobacco 105 (e.g., moist cured, fermented smokeless tobacco)can be advantageously needled together with structural fibers 110 sothat the smokeless tobacco is entangled and secured in the structuralfibers. In particular embodiments, the smokeless tobacco 105 is notcompacted (e.g., it is not subjected to a mechanical compacting process)or chemically treated (e.g., by the use of a binding agent) during theneedling process. As such, the smokeless tobacco 105 can surprisinglyand advantageously retain a desired range of moisture, flavor andtactile characteristics after the needling process is complete and thenonwoven needled articles 100 are ready for packaging. Moreover, theneedling process used to secure the smokeless tobacco 105 to thestructural fibers 110 may be unlike conventional needling of traditionalnonwoven textiles. In particular, it will be understood from thedescription herein that the smokeless tobacco 105 can be surprisinglyand advantageously entangled within a web of structural fibers byneedling without compromising the moisture, flavor and tactilecharacteristics of the smokeless tobacco. Furthermore, when smokelesstobacco is used, the nonwoven needled article 100 provides the adulttobacco consumer with a tobacco product that offers advantages comparedto a “pinch” or dip of loose tobacco in terms of handling, placement inthe mouth, stability in the mouth, and removal from the mouth.

As shown in FIG. 8, a typical needle loom 1 contains a needle board 3,which is the base unit into which the needles 4 are inserted and held.The needle board 3 then fits into the needle beam 5, which holds theneedle board 3 in place. A needle loom also includes a bed plate 7,which is positioned underneath the layers of structural fiber andsmokeless tobacco, and a stripper plate 9, which is positioned above thelayers of structural fiber and smokeless tobacco. In some circumstances,the web passing through the needle loom 1 may include a backing layer111. A backing layer can be fibrous or non-fibrous. A fibrous backinglayer contributes structural fibers to the final needled tobacco article100, while a non-fibrous backing layer does not contribute structuralfibers to the final needled tobacco-entangled fabric 100 and can bepeeled away or removed after the needling process is completed. Forexample, the smokeless tobacco 105, which may, for example, comprisesmokeless tobacco in shredded or cut form, can be deposited on thebacking layer 111 followed by a layer of structural fibers and advancedalong a feed conveyor 11 and into the space between the bed plate 7 andthe stripper plate 9. Each of the bed plate 7 and the stripper plate 9includes a set of holes corresponding to the needles 4 so that theneedles 4 are aligned to pass in and out of the holes in the plates 7and 9. During the return of the needles 4 to an upward position, thestripper plate 9 strips the fibers from the needles 4 so that the layersof structural fiber and smokeless tobacco can advance through the needleloom 1. Advancement through the needle loom 1 can be facilitated by afeed roll 11 and an exit roll 13.

FIG. 9 shows representative needles 4 that can be employed in the needleloom 1 to penetrate the layers of structural fibers and smokelesstobacco 105 for use in the aforementioned needle punching process tomanufacture the needled tobacco articles 100. Simply by way of example,needles 4 can have different shapes (e.g., pinch blades, star blades,and conical blades) and different barb configurations (e.g., placement,angle, and shape). In certain embodiments, the needle loom 1 containsneedles 4 that are all the same shape and configuration; in certainembodiments, the needle loom 1 contains needles 4 having more than oneshape and/or configuration. It would be understood that the particularshape and configuration of the needles 4 used in the needle punchingprocess, as well as the number of penetrations per square inch (ppsi)and the penetration depth of the needles 4, would be dependent upon thecharacteristics of the particular structural fibers used, thecharacteristics of the smokeless tobacco used, the number of layers ofeach, and the desired properties of the finished needled tobacco article100.

As shown in FIG. 10, the needle loom beam 5 is configured to reciprocateup and down so that the needles 4 penetrate in and out of thecorresponding holes of the plates 7 and 9. In doing so, the needlespenetrate the structural fibers 110 and the smokeless tobacco 105 whilebarbs on the blade of each needle 4 can pick up fibers (e.g., primarilystructural fibers and only incidentally tobacco's fibrous structures 105a) on the downward movement and carry these fibers the depth of thepenetration. The reciprocation of the needles 4 occurs repeatedly whilethe feed rolls 11 and exit rolls 13 force the layers of smokelesstobacco and structural fiber layers through the needle loom 1 as theneedles reorient the fibers from a predominantly horizontal orientationto a generally vertical orientation.

Thus, in the aforementioned embodiment, the needled tobacco-entangledfabric can be formed using a needling process that includes needlingstructural fibers with smokeless tobacco. One of the structural fibers110 that can be used in the needle loom 1 with the smokeless tobacco 105can be cotton fiber. It should be understood from the descriptionherein, however, that the structural fibers are not necessarily limitedto cotton. For example, structural fibers can include other types ofnatural fibers (e.g., wool, flax, jute, bamboo) as well as acrylics,nylon, polyester, polyethylene, polypropylene, polyvinyl chloride,polylactic acid, polyvinyl alcohol, and rayon, viscose or other modifiedcellulosic fibers (e.g., reconstituted cellulosic fibers as discussedbelow). A variety of methods and combinations of methods are suitablefor providing the structural fibers use in a needling process to createthe tobacco-entangled fabric. For example, the webs/substrates/fibersource for fibers can be obtained from dry laid, air laid, wet laid,spun laced, melt blown, electro spun, and/or force spun; fibers suppliedby any of these processes may be further processed into fabrics withneedle punching or other web forming processes prior to their use informing tobacco-entangled fabrics. In some embodiments, the structuralfibers are dry laid natural fibers. In other embodiments, the fibers aremelt-blown or spun bond polymeric fibers. In addition, structural fibersused in the needling process to produce a needled tobacco article can beprovided from woven or nonwoven fabrics provided that the fabricprovides a sufficient number of ‘loose’ structural fibers that areavailable to participate in the needling process and secure thesmokeless tobacco in the finished article. The needling process,however, can turn a loosely woven fabric of structural fibers into anonwoven network of structural fibers due to a reduction in the order ofthe structural fibers. In addition, using a lower denier (e.g., a lowerlinear mass density) may provide a softer tobacco-entangled fabrichaving a pleasant mouth feel.

Referring now to FIG. 11, some embodiment of a tobacco-entangled fabricpieces can have a shape or a layer structure that is different from theparticular embodiment of the article 100 depicted in FIG. 1. Forexample, in one alternative embodiment of a needled tobacco-entangledfabric piece 100′ for use in the mouth, the smokeless tobacco 105 isneedled between two layers 110 a and 110 b of staple fibers. Similar topreviously described embodiments, the needled tobacco-entangled fabricpiece 100′ in this embodiment includes a predetermined portion ofsmokeless tobacco 105, and the smokeless tobacco 105 can be exposedalong a number of exterior surfaces of the tobacco-entangled fabricpiece 100′. Further, the needled tobacco-entangled fabric pieces 100′can be packaged in a container 52 with a lid 54 (FIG. 1) along with aplurality of similarly shaped articles 100′ so that an adult tobaccoconsumer can conveniently select any of the tobacco-entangled fabricpieces 100′ therein for use in the mouth and receive a substantiallyidentical portion of the smokeless tobacco 105. Although suchtobacco-entangled fabric pieces 100′ for use in the mouth can be made innumerous ways, the tobacco-entangled fabric shown in FIG. 11 can bemanufactured using the methods described in, for example, Example 25 or26, and cut into tobacco-entangled fabric pieces. The tobacco-entangledfabric piece depicted in FIG. 11 is approximately 0.5 inch by 1.0 inchand has a thickness of about 0.25 inches.

FIGS. 12A-C show micrographs of exemplary needled tobacco-entangledfabrics in accordance with some embodiments described herein. FIG. 12Ashows a needled tobacco-entangled fabric in which a layer of structuralfibers was placed on the needle loom, a layer of smokeless tobacco wasplaced on top of the structural fibers, another layer of structuralfibers was placed on top of the smokeless tobacco, and then needled witha penetration depth of 6 mm for the first pass and 3.2 mm for the secondpass. FIG. 12B shows another needled tobacco article in which a backinglayer was placed on the needle loom, followed by layers of smokelesstobacco, structural fibers, smokeless tobacco and structural fibers.Following needling, at a needle penetration depth of 8.5 mm, the backinglayer was removed (e.g., peeled away), leaving an exposed layer ofsmokeless tobacco secured by the fibers. FIG. 12C shows yet anotherneedled tobacco-entangled fabric in which a backing layer was placed onthe loom, followed by layers of smokeless tobacco, structural fibers andsmokeless tobacco. After needling, at a penetration depth of 8.5 mm, thebacking layer was removed, leaving two exposed layers of smokelesstobacco secured to both sides of the fiber layer.

Thus, in accordance with some methods of making needledtobacco-entangled fabric 100 or 100′ that include smokeless tobacco 105,a needling process includes at least one layer of smokeless tobacco andat least one layer of structural fibers passed through a needle loom 1.In particular embodiments, the first layer placed on the needle loom canbe the smokeless tobacco, the structural fiber, or a backing layer thatdoes not contribute fibers to the needled tobacco-entangled fabric andcan be removed after the needling process. Using the methods describedherein, a needled tobacco-entangled fabric can be manufactured to haveone of a number of different combinations of smokeless tobacco layersand structural fiber layers with single passes through the needle loom 1or multiple passes through the needle loom 1, as the layers are beingconstructed or after all the layers have been constructed.

The parameters of the actual needling process will depend upon thefeatures of the tobacco's fibrous structures, the features of thestructural fibers, the number of layers of each, and the type of loom.Those of skill in the art would understand that the size and shape ofthe needles as well as the needle density, the penetration depth of theneedles, and the feed rate of the material through the loom all can bevaried to achieve a nonwoven needled tobacco-entangled fabric having thedesired properties. For example, lower needle density and/or shallowerneedle penetration can be used to produce a less dense, loosertobacco-entangled fabric, while a higher needle density and/or a deeperneedle penetration can be used to produce a denser, tightertobacco-entangled fabric. For example, a puncture density of betweenabout 100 penetrations per square inch (ppsi) and about 2000 ppsi (e.g.,about 200 ppsi to about 1000 ppsi; about 400 ppsi to about 800 ppsi) canbe used to produce the needled tobacco-entangled fabrics describedherein.

Needling can also be used in combination with polymeric structuralfibers produced using melt-blowing or spun bonding processes. Forexample, referring now to FIG. 13, a melt-blown smokelesstobacco/polymeric structural fiber layered composite can be additionallyconveyed to a needle loom beam 65. The needle loom beam 65 is configuredto reciprocate up and down so that the needles 64 penetrate in and outof corresponding holes in plates 67 and 69. In doing so, the needlespenetrate the polymeric structural fibers 110, smokeless tobacco 105,and the fibers of web 132 while barbs on the blade of each needle 64 canpick up any of the fibers, including tobacco fibers, on the downwardmovement and carry these fibers the depth of the penetration. Thereciprocation of the needles 64 occurs repeatedly while the rollers 11,12, 13, and 14 forces the composite through the needle loom 60 as theneedles reorient the fibers from a predominantly horizontal orientationto a generally vertical orientation, thus producing a melt-blown andneedled tobacco-entangled fabric.

Given that the needled tobacco-entangled fabric are intended for use inthe mouth, the manufacturing process may include a scanning step with ametal detector and/or a magnet to detect any broken needles remaining inthe product after needling. Under appropriate needling conditions,needle breakage should be infrequent, but, for precautionary reasons,the needled composite of smokeless tobacco and structural fibers exitingthe loom or the cut or punched needled tobacco-entangled fabric can bescanned with a metal detector and/or a magnet for any metal, which wouldindicate the presence of a fragment from a broken needle.

Spun Lace (Hydroentanglement)

Spun lace, also known as hydroentanglement, is a process that uses fluidforces to lock the fibers together. For example, fine water jets can bedirected through a web of structural fibers, which is supported by aconveyor belt, to entangle the structural fibers together and/or withthe tobacco's fibrous structures. Entanglement occurs when the waterstrikes the web and the fibers are deflected. The vigorous agitationwithin the web causes the fibers to become entangled. For example, aspun lacing process can be used to entangle smokeless tobacco with a webof structural fibers. For example, a cotton web may be spun laced priorto being needled with smokeless tobacco.

The tobacco-entangled fabric, in some embodiments, can be made bylayering smokeless tobacco with webs of carded cotton fibers andentangling the tobacco's fibrous structures with the cotton structuralfibers by passing fine liquid jets through the layered structure. Inother embodiments, smokeless tobacco may be intermingled within anon-cohesive web of structural fibers and spun laced to form thetobacco-entangled fabric. In some embodiments, the smokeless tobacco istreated or encapsulated to retain soluble components during the spunlacing process. In some embodiments, soluble tobacco components areextracted from the smokeless tobacco prior to the spun lacing processand are added back to the finished spun laced product after drying. Insome embodiments, the spun-lacing liquid is a solution of flavorants orother additives.

Similar to spun lacing, the tobacco-entangled fabric may also be air-jetentangled using high velocity streams of gas to entangle the fibers. Inother embodiments, air jets can be used to intermingle smokeless tobaccowith structural fibers prior to bonding of the structural fibers to forma cohesive and/or dimensionally stable tobacco-entangled fabric.

Thermal Bonding

Thermal bonding is the process of using heat to bond or stabilize a webstructure. Polymeric structural fibers can be thermally bonded tostabilize or further stabilize the tobacco-entangled fabric. In someembodiments of thermal bonding, other energy sources are applied toincrease the temperature of the polymeric material of the structuralfibers and to bond or attach the structural fibers to each other tocreate a network of fibers with increased fabric strength anddimensionally stability. For example, electrically heated surfaces,ultrasonic bonding, infrared energy, radio frequency energy andmicrowave energy are particular sources of energy for thermal bonding.

As discussed above, melt-blowing can result in at least some thermalbonding during the process of extruding and attenuating the fibers. Spunbond processes use thermal bonding techniques to bond the fibers afterthe fibers are deposited. In some embodiments, the fiber web is passedbetween heated calendar rollers to bond one or more portions of the web.Embossed rolls can also be used to provide point bonding, while addingsoftness and flexibility to the tobacco-entangled fabric.

Stitch bonding, point bonding and quilting are methods of applyingpatterns to nonwoven fabrics including tobacco-entangled fabrics. Theseare forms of thermal bonding typically achieved with ultrasonic bondingprocesses although other energy sources and related equipment can beused to create particular patterns of bonding within the network offibers.

Bonding between the structural fibers can also be accomplished byincorporating a low melting temperature polymer into the network ofstructural fibers. The low melting temperature polymer could beintroduced into the network in the form of fibers, beads, or randomshapes. The low melting temperature polymer fibers, beads, or randomshapes can be dispersed within the network of structural fibers. In someembodiments, the low melting temperature polymer have a melting point ofbetween about 60° C. and 150° C. For example, low molecular weightfibers of polyethylene and polypropylene can be used as the low meltingtemperature polymer. In other embodiments, the low melting temperaturepolymer can polyvinyl acetate or various waxes. For example, the lowermelting temperature polymers, fibers, beads or random shapes could havea melting point of about 60 C to 150 C. By heating the composite of thestructural fibers, the smokeless tobacco, and the low meltingtemperature polymeric material to a temperature between the meltingpoints of the two different materials, the low melting temperaturepolymeric material can be selectively melted and thus bond tosurrounding fibers to create a desired level of bonding within thetobacco-entangled fabric.

Thermal bonding techniques can also be used in combination with any ofthe other techniques discussed herein.

Chemical Bonding

Chemically bonding a web by coating the fibers with a binder, such aslatex emulsions or solution polymers, is typically used in wet laidprocesses. For dry laid systems, adhesive materials in the form of beadsor small random shapes can be intermingled with the network ofstructural fibers and activated with heat and/or pressure to bond thenetwork into the tobacco-entangled fabric. In some embodiments, siliconeor polyvinyl acetate is used as a chemical adhesive. In someembodiments, sodium alginate is added to the network and then a calciumsalt added to make the alginate insoluble within the network and thusbond surrounding fibers. Chemical bonding can be used with any othertechnique of forming structural fibers and/or intermingling smokelesstobacco with the structural fibers.

Product Components

The tobacco-entangled fabric 100 includes smokeless tobacco 105 andstructural fibers 110. At least a portion of the structural fibers 110can include a mouth-stable material such that the tobacco-entangledfabric remains cohesive when placed in an adult tobacco consumer'smouth. The tobacco-entangled fabric 100 can optionally include one ormore flavorants and other additives.

Structural Fibers

A variety of fibers are suitable for use in the tobacco-entangled fabric100. At least a portion of the structural fibers 110 can be mouth-stablewhen exposed to saliva and other mouth fluids when placed within anadult tobacco consumer's mouth. As used herein, “mouth-stable” meansthat the material remains cohesive when placed in an adult tobaccoconsumer's mouth for 1 hour. The structural fibers 110 can includenatural fibers, synthetic fibers, or a combination thereof. Naturalfibers include cotton, wool, flax, jute, and bamboo. The structuralfibers can include polymeric materials, such as acrylics, nylon,polyester, polyethylene, polypropylene, polyurethane (such as DESMOPANDP 9370A available from Bayer), polyvinyl chloride, polylactic acid,polyvinyl alcohol, and rayon, viscose or other modified cellulosicfibers, and combinations thereof. In some embodiments, a mouth-stablefiber is biodegradable. As used herein, “biodegradable” means a materialthat meets the requirements of ASTM D6400-04, Standard Specification forCompostable Plastics. Suitable biodegradable materials will decompose innatural aerobic (composting) and anaerobic (landfill) environments, yetremain stable within a consumer's mouth for a suitable period of time(e.g., 1 hour). Examples of biodegradable materials include aliphaticpolyesters; polyhydroxyalkanoates such as poly-3-hydroxybutyrate,polyhydroxyvalerate, and polyhydroxyhexanoate; polylactic acid;polybutylene succinate; polycaprolactone; polyanhydrides; polyvinylalcohol; various starch derivatives; and cellulose esters like celluloseacetate and nitrocellulose and their derivatives (e.g., celluloid).

The structural fibers can include multiple materials. In someembodiments, structural fibers of a first material are interspersed orlayered with structural fibers of a second material. For example, alower melting temperature polymer can function as a binder which may bea separate fiber interspersed with higher melting structural fibers. Inother embodiments, structural fibers can be bicomponent ormulticomponent fibers made of different materials. For example, a lowermelting sheath can surround a higher melting core, which can help withthermal bonding processes. The components of a multi-component fiber canalso be extruded in a side-by-side configuration. For example, differentpolymeric materials can be co-extruded and drawn in a melt-blowing orspun bond process to form the multi-component structural fibers.

The structural fibers can also be formed from multicomponent fibers thatfibrillate to become multiple fibers. The multi component fibers canbecome fibrillated by applying force to the fibers. For example,hydroentanglement can be used to fibrillate a multicomponent fiber. Inother embodiments, a pounding and/or crushing force (e.g., a hammer orpressure roller) can be applied to the multicomponent fiber. In someembodiments, a needling process can fibrillate a multicomponent fiber.In other embodiments, multicomponenet fibers can be needled withoutbecoming fibrillated, but become fibrillated in subsequent processesand/or during use by an adult tobacco consumer. In some embodiments, onemulticomponent fiber can be fibrillated into many (e.g., 10 or more)microfibers. In certain embodiments, the structural fibers include atleast one mouth-stable material and at least one mouth-dissolvablematerial such that the tobacco-entangled fabric will loosen but remaincohesive as the mouth-dissolvable material dissolves away. In someembodiments, the network of structural fibers includes mouth-dissolvablefibers and mouth-stable fibers. As used herein, “mouth-dissolvable”means that the material breaks down within 1 hour after being exposed tosaliva and other mouth fluids when placed in an adult tobacco consumer'smouth. Mouth-dissolvable materials include hydroxypropyl cellulose(HPC), methyl hydroxypropyl cellulose (HPMC), polyvinyl alcohol (PVOH),PVP, polyethylene oxide (PEO), starch and others. Mouth-dissolvablematerials could be combined with flavors, sweeteners, milled tobacco andother functional ingredients. In other embodiments, multi-componentfibers include a mouth-stable material and a mouth-dissolvable material.

In some embodiments, the structural fibers 110 include reconstitutedcellulosic fibers. Reconstituted cellulosic fibers can be created fromvarious woods and annual plants by physically dissolving the wood orplant material in a suitable solvent, such as methylmorpholine oxide(MNNO) monohydrate. The concentration of cellulose in the solution canbe between 6 weight and 15 weight percent. The solution can then be spun(e.g., melt-blown or spun bond) at a temperature of between 70° C. and120° C. to create reconstituted cellulosic fibers. In some embodiments,the reconstituted cellulosic fibers are made using tobacco material(e.g., tobacco stems). Reconstituted tobacco cellulosic fibers can thenbe entangled with smokeless tobacco having natural cellulosic fibers tocreate a tobacco-entangled fabric having tobacco-derived structuralfibers. The reconstituting process changes the composition of thetobacco and removes many of the soluble tobacco components normallyfound in smokeless tobacco.

In still other embodiments, milled tobacco could be combined into apolymeric structural fiber such that the polymeric material at leastpartially encapsulates the milled tobacco. For example, milled tobaccocould be added to a molten polymer (e.g., polypropylene) in amounts fromabout 10% by weight up to about 80% by weight and extruded in amelt-blowing or spun bond process. The milled tobacco can provide aunique texture to the structural fibers while the polymeric materialremains mouth stable and cohesive. The amount of structural fiber 110used in the tobacco-entangled fabric 100 can depend on the desiredflavor profile and desired mouth feel. In some embodiments, thetobacco-entangled fabric 100 includes at least 0.5 weight percentstructural fibers, which can increase the likelihood that thetobacco-entangled fabric 100 maintains its cohesion during packaging,transport, handling, and use by an adult tobacco consumer. In someembodiments, the tobacco-entangled fabric 100 includes up to 20 weightpercent structural fibers. In some embodiments, the tobacco-entangledfabric 100 includes between 0.5 and 10 weight percent structural fibers.For example, the tobacco-entangled fabric 100 can have between 1.0 and7.0 weight percent structural fibers.

Tobacco

Smokeless tobacco is tobacco suitable for use in an orally used tobaccoproduct. By “smokeless tobacco” it is meant a part, e.g., leaves, andstems, of a member of the genus Nicotiana that has been processed.Exemplary species of tobacco include N. rustica, N. tabacum, N.tomentosiformis, and N. sylvestris. Suitable tobaccos include fermentedand unfermented tobaccos. In addition to fermentation, the tobacco canbe processed using other techniques. For example, tobacco can beprocessed by heat treatment (e.g., cooking, toasting), flavoring, enzymetreatment, expansion and/or curing. Both fermented and non-fermentedtobaccos can be processed using these techniques. In other embodiments,the tobacco can be unprocessed tobacco. Specific examples of suitableprocessed tobaccos include dark air-cured, dark fire cured, burley, fluecured, and cigar filler or wrapper, as well as the products from thewhole leaf stemming operation. In some embodiments, smokeless tobaccoincludes up to 70% dark tobacco on a fresh weight basis. For example,tobacco can be conditioned by heating, sweating and/or pasteurizingsteps as described in U.S. Publication Nos. 2004/0118422 or2005/0178398. Fermenting typically is characterized by high initialmoisture content, heat generation, and a 10 to 20% loss of dry weight.See, e.g., U.S. Pat. Nos. 4,528,993; 4,660,577; 4,848,373; and5,372,149. In addition to modifying the aroma of the leaf, fermentationcan change either or both the color and texture of a leaf. Also duringthe fermentation process, evolution gases can be produced, oxygen can betaken up, the pH can change, and the amount of water retained canchange. See, for example, U.S. Publication No. 2005/0178398 and Tso(1999, Chapter 1 in Tobacco, Production, Chemistry and Technology, Davis& Nielsen, eds., Blackwell Publishing, Oxford). Cured, or cured andfermented tobacco can be further processed (e.g., cut, expanded,blended, milled or comminuted) prior to incorporation into the smokelesstobacco product. The tobacco, in some embodiments, is long cut fermentedcured moist tobacco having an oven volatiles content of between 48 and50 weight percent prior to mixing with the structural fibers andoptionally flavorants and other additives.

The tobacco can, in some embodiments, be prepared from plants havingless than 20 μg of DVT per cm² of green leaf tissue. For example, thetobacco particles can be selected from the tobaccos described in U.S.Patent Publication No. 2008/0209586, which is hereby incorporated byreference. Tobacco compositions containing tobacco from such low-DVTvarieties exhibits improved flavor characteristics in sensory panelevaluations when compared to tobacco or tobacco compositions that do nothave reduced levels of DVTs.

Green leaf tobacco can be cured using conventional means, e.g.,flue-cured, barn-cured, fire-cured, air-cured or sun-cured. See, forexample, Tso (1999, Chapter 1 in Tobacco, Production, Chemistry andTechnology, Davis & Nielsen, eds., Blackwell Publishing, Oxford) for adescription of different types of curing methods. Cured tobacco isusually aged in a wooden drum (i.e., a hogshead) or cardboard cartons incompressed conditions for several years (e.g., two to five years), at amoisture content ranging from 10% to about 25%. See, U.S. Pat. Nos.4,516,590 and 5,372,149. Cured and aged tobacco then can be furtherprocessed. Further processing includes conditioning the tobacco undervacuum with or without the introduction of steam at varioustemperatures, pasteurization, and fermentation. Fermentation typicallyis characterized by high initial moisture content, heat generation, anda 10 to 20% loss of dry weight. See, e.g., U.S. Pat. Nos. 4,528,993,4,660,577, 4,848,373, 5,372,149; U.S. Publication No. 2005/0178398; andTso (1999, Chapter 1 in Tobacco, Production, Chemistry and Technology,Davis & Nielsen, eds., Blackwell Publishing, Oxford). Cure, aged, andfermented smokeless tobacco can be further processed (e.g., cut,shredded, expanded, or blended). See, for example, U.S. Pat. Nos.4,528,993; 4,660,577; and 4,987,907.

The smokeless tobacco can be processed to a desired size. For example,long cut smokeless tobacco typically is cut or shredded into widths ofabout 10 cuts/inch up to about 110 cuts/inch and lengths of about 0.1inches up to about 1 inch. Double cut smokeless tobacco can have a rangeof particle sizes such that about 70% of the double cut smokelesstobacco falls between the mesh sizes of −20 mesh and 80 mesh.Accordingly, the smokeless tobacco can include fibrous structures thatbecome entangled with the structural fibers. Although powdered or milledtobacco can also be included in the smokeless tobacco products describedherein (e.g., within the structural fibers), the fibrous structures inpowdered and milled tobacco are not of sufficient length to permitentanglement with structural fibers.

The smokeless tobacco can have a total oven volatiles content of about10% by weight or greater; about 20% by weight or greater; about 40% byweight or greater; about 15% by weight to about 25% by weight; about 20%by weight to about 30% by weight; about 30% by weight to about 50% byweight; about 45% by weight to about 65% by weight; or about 50% byweight to about 60% by weight. Those of skill in the art will appreciatethat “moist” smokeless tobacco typically refers to tobacco that has anoven volatiles content of between about 40% by weight and about 60% byweight (e.g., about 45% by weight to about 55% by weight, or about 50%by weight). As used herein, “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110° C. for 3.25 hours. Thetobacco-entangled fabric can have a different overall oven volatilescontent than the oven volatiles content of the smokeless tobacco used tomake the tobacco-entangled fabric. The processing steps described hereincan reduce or increase the oven volatiles content. The overall ovenvolatiles content of the tobacco-entangled fabric is discussed below.

The tobacco-entangled fabric can include between 15 weight percent and85 weight percent smokeless tobacco on a dry weight basis. The amount ofsmokeless tobacco in a fabric piece on a dry weight basis is calculatedafter drying the tobacco-entangled fabric in a pre-warmed forced draftoven at 110° C. for 3.25 hours. The remaining non-volatile material isthen separated into tobacco material and structural fiber material. Thepercent smokeless tobacco in the tobacco-entangled fabric is calculatedas the weight smokeless tobacco divided by the total weight of thenon-volatile materials. In some embodiments, the tobacco-entangledfabric includes between 20 and 60 weight percent tobacco on a dry weightbasis. In some embodiments, the tobacco-entangled fabric includes atleast 28 weight percent tobacco on a dry weight basis. For example, atobacco-entangled fabric can include a total oven volatiles content ofabout 57 weight percent, about 3 weight percent structural fibers (suchas cotton), and about 40 weight percent smokeless tobacco on a dryweight basis.

In some embodiments, a plant material other than tobacco is used as atobacco substitute in the tobacco-entangled fabric. The tobaccosubstitute can be a herbal composition. Herbs and other edible plantscan be categorized generally as culinary herbs (e.g., thyme, lavender,rosemary, coriander, dill, mint, peppermint) and medicinal herbs (e.g.,Dahlias, Cinchona, Foxglove, Meadowsweet, Echinacea, Elderberry, Willowbark). In some embodiments, the tobacco is replaced with a mixture ofnon-tobacco plant material. Such non-tobacco compositions may have anumber of different primary ingredients, including but not limited to,tea leaves, red clover, coconut flakes, mint leaves, ginseng, apple,corn silk, grape leaf, and basil leaf. The plant material typically hasa total oven volatiles content of about 10% by weight or greater, e.g.,about 20% by weight or greater; about 40% by weight or greater; about15% by weight to about 25% by weight; about 20% by weight to about 30%by weight; about 30% by weight to about 50% by weight; about 45% byweight to about 65% by weight; or about 50% by weight to about 60% byweight.

Flavorants and Additives

Flavors and other additives can be included in the compositionsdescribed herein, and can be added during a variety of different stagesof the various processes described herein. For example, any of theinitial components, including the structural fibers, can be provided ina flavored form. In some embodiments, flavorants and/or other additivesare included in the smokeless tobacco. Flavorants and/or other additivescan be absorbed into to the tobacco-entangled fabric 100 after thestructural fibers and the tobacco's cellulosic fibers are combined. Inother embodiments, flavorants and/or other additives are mixed with thestructural fibers prior to mixing in the smokeless tobacco.Alternatively or additionally, flavor can be applied to thetobacco-entangled fabric prior to being further processed (e.g., cut orpunched into shapes), or flavor can be applied to the tobacco-entangledfabric prior to packaging. Referring to FIG. 15A, for example, someembodiments of a tobacco-entangled fabric 200A are equipped withflavors, in the form of flavor strips 205.

Suitable flavorants include wintergreen, cherry and berry typeflavorants, various liqueurs and liquors such as Dramboui, bourbon,scotch, whiskey, spearmint, peppermint, lavender, cinnamon, cardamon,apium graveolents, clove, cascarilla, nutmeg, sandalwood, bergamot,geranium, honey essence, rose oil, vanilla, lemon oil, orange oil,Japanese mint, cassia, caraway, cognac, jasmin, chamomile, menthol,ilangilang, sage, fennel, piment, ginger, anise, coriander, coffee,liquorish, and mint oils from a species of the genus Mentha. Mint oilsuseful in particular embodiments of the tobacco-entangled fabric 100include spearmint and peppermint.

In some embodiments, flavorants are coated on the structural fibers. Forexample, flavorants can be included in a dissolvable carrier anddispersed into the tobacco-entangled fabric. Flavorants can also beincluded in the form of flavor beads, which can be dispersed within thetobacco-entangled fabric. For example, the tobacco-entangled fabriccould include the beads described in U.S. Patent Application Publication2010/0170522, which is hereby incorporated by reference. In someembodiments, flavor bead are positioned within a tobacco-entangledfabric pouch. Other arrangements of tobacco-entangled fabric combinedwith flavor beads are also contemplated.

In some embodiments, the amount of flavorants in the tobacco-entangledfabric 100 is limited to less than 10 weight percent in sum. In someembodiments, the amount of flavorants in the tobacco-entangled fabric100 is limited to be less than 5 weight percent in sum. For example,certain flavorants can be included in the tobacco-entangled fabric 100in amounts of about 3 weight percent.

Other optional additives include as fillers (e.g., starch, di-calciumphosphate, lactose, sorbitol, mannitol, and microcrystalline cellulose),soluble fiber (e.g., Fibersol from Matsushita), calcium carbonate,dicalcium phosphate, calcium sulfate, and clays), lubricants (e.g.,lecithin, stearic acid, hydrogenated vegetable oil, mineral oil,polyethylene glycol 4000-6000 (PEG), sodium lauryl sulfate (SLS),glyceryl palmitostearate, sodium benzoate, sodium stearyl fumarate,talc, and stearates (e.g., Mg or K), and waxes (e.g., glycerolmonostearate, propylene glycol monostearate, and acetylatedmonoglycerides), plasticizers (e.g., glycerine, propylene glycol,polyethylene glycol, sorbitol, mannitol, triacetin, and 1,3 butanediol), stabilizers (e.g., ascorbic acid and monosterol citrate, BHT, orBHA), artificial sweeteners (e.g., sucralose, saccharin, and aspartame),disintegrating agents (e.g., starch, sodium starch glycolate, crosscaramellose, cross linked PVP), pH stabilizers, or other compounds(e.g., vegetable oils, surfactants, and preservatives). Some compoundsdisplay functional attributes that fall into more than one of thesecategories. For example, propylene glycol can act as both a plasticizerand a lubricant and sorbitol can act as both a filler and a plasticizer.

Oven volatiles, such as water, may also be added to thetobacco-entangled fabric 100 to bring the oven volatiles content of thetobacco-entangled fabric into a desired range. In some embodiments,flavorants and other additives are included in a hydrating liquid.

Oven Volatiles

The tobacco-entangled fabric 100 can have a total oven volatiles contentof between 10 and 65 weight percent. In some embodiments, the overalloven volatiles content is 10% by weight or greater, e.g., about 20% byweight or greater; about 40% by weight or greater; about 15% by weightto about 25% by weight; about 20% by weight to about 30% by weight;about 30% by weight to about 50% by weight; about 45% by weight to about65% by weight; or about 50% by weight to about 60% by weight. The ovenvolatiles include water and other volatile compounds, which can be apart of the tobacco, the structural fibers, the flavorants, and/or otheradditives. As used herein, the “oven volatiles” are determined bycalculating the percentage of weight loss for a sample after drying thesample in a pre-warmed forced draft oven at 110° C. for 3.25 hours. Thestructural fibers may absorb some of the oven volatiles during variousprocesses, however the processes can be controlled to have an overalloven volatiles content in a desired range. In some embodiments, waterand/or other volatiles are added to the tobacco-entangled fabric toraise the oven volatiles content to a desired range. In someembodiments, the oven volatiles content of the tobacco-entangled fabric100 is between 50 and 61 weight percent. For example, the oven volatilescontent of smokeless tobacco 105 used in the various processes describedherein can be about 57 weight percent and the target oven volatilescontent of the resulting tobacco-entangled fabric can be about 57 weightpercent. In other embodiments, the overall oven volatiles content can bebetween 10 and 30 weight percent.

Product Configurations

A smokeless tobacco product comprising a tobacco-entangled fabric asdescribed herein can have a number of different configurations, e.g.,can have the configuration of the piece of tobacco-entangled fabric 100depicted in FIG. 1 or 11, or can have a shape or a layer structure thatis different from the particular embodiment depicted in FIG. 1 or 11.For example, referring to FIGS. 14A-K, the tobacco-entangled fabric100A-K can be formed in a shape that promotes improved oral positioningfor the adult tobacco consumer, improved packaging characteristics, orboth. In some circumstances, the tobacco-entangled fabric 100 can beconfigured to be: (A) an elliptical shaped tobacco-entangled fabric100A; (B) an elongated elliptical shaped tobacco-entangled fabric 100B;(C) a semi-circular tobacco-entangled fabric 100C; (D) a square- orrectangular-shaped tobacco-entangled fabric 100D; (E) a football-shapedtobacco-entangled fabric 100E; (F) an elongated rectangular-shapedtobacco-entangled fabric 100F; (G) boomerang-shaped tobacco-entangledfabric 100G; (H) a rounded-edge rectangular-shaped tobacco-entangledfabric 100H; (I) teardrop- or comma-shaped tobacco-entangled fabric100I; (J) bowtie-shaped tobacco-entangled fabric 100J; and (K)peanut-shaped tobacco-entangled fabric 100K. Alternatively, thetobacco-entangled fabric 100 can be shaped to have different thicknessesor dimensionality, such that a beveled article (e.g., a wedge) isproduced (see, for example, the tobacco-entangled fabric depicted inFIG. 14L) or a hemi-spherical shape is produced.

The tobacco-entangled fabric can be cut or sliced longitudinally orlaterally to produce a variety of smokeless tobacco compositions havingdifferent tobacco/fiber profiles. For example, the texture (e.g.,softness and comfort in the mouth), taste, level of oven volatiles(e.g., moisture), flavor release profile, and overall adult tobaccoconsumer satisfaction of a tobacco-entangled fabric will be dependentupon the concentration and distribution of tobacco material, and thenumber of layers, thicknesses, and dimensions and type(s) of melt-blownpolymeric fibers, all of which effects the density and integrity of thefinal product. Similar to previously described embodiments, thetobacco-entangled fabric pieces 100A-L depicted in FIGS. 14A-L can beconfigured to include a predetermined portion of smokeless tobacco 105,and the smokeless tobacco 105 can be exposed along a number of exteriorsurfaces of the articles 100A-L. Further, the articles 100A-L can bepackaged in a container 52 with a lid 54 (FIG. 1) along with a pluralityof similarly shaped tobacco-entangled fabric pieces 100A-L so that anadult tobacco consumer can conveniently select any of the similarlyshaped pieces of tobacco-entangled fabric pieces 100 therein for use inthe mouth and receive a substantially identical portion of the smokelesstobacco 105.

Referring to FIG. 15A, some embodiments of a tobacco-entangled fabric200A can be equipped with flavorants, in the form of flavor strips 205.The flavor strips 205 can be applied to the tobacco-entangled fabricsuch that both the smokeless tobacco 105 and the flavor strip 205 areexposed along exterior surfaces of the tobacco-entangled fabric piece200A. In some embodiments, the flavor strips 205 are applied to thetobacco-entangled fabric 200A before cutting or punching thetobacco-entangled fabric into the desired shape.

The tobacco-entangled fabric can be manipulated in a number of differentways. For example, as shown in FIG. 15B, particular embodiments of thetobacco-entangled fabric 200B can be wrapped or coated in an edible ordissolvable film. The dissolvable film can readily dissipate when thetobacco-entangled fabric 200B is placed in an adult tobacco consumer'smouth, thereby providing the adult tobacco consumer with the tactilefeel of the smokeless tobacco 105 along the exterior of the article 200Bonce dissolved. In addition, or in the alternative, some embodiments ofthe tobacco-entangled fabric can be embossed or stamped with a design(e.g., a logo, an image, a trademark, a product name, or the like). Forexample, as shown in FIG. 15C, the tobacco-entangled fabric 200C can beembossed or stamped with any type of design 206 including, but notlimited to, an image. The design can be formed directly into or ontosmokeless tobacco material 105 arranged along the exterior of thetobacco-entangled fabric 200C. In other embodiments, a structural fiberexterior can be embossed. The design 206 also can be embossed or stampedinto those embodiments having a dissolvable film applied thereto, asillustrated in FIG. 15B.

In some embodiments, the tobacco-entangled fabric is used in combinationwith other tobacco and non-tobacco ingredients to form a variety ofsmokeless tobacco products. For example, the tobacco-entangled fabriccan form a pouch that surrounds a mass of smokeless tobacco and/or otheringredients. The contents of the pouch can include flavor beads asdiscussed above. Other smokeless tobacco products includingtobacco-entangled fabric are also contemplated.

Packaging

The tobacco-entangled fabric described herein can be packaged in anynumber of ways for convenient use. As previously described, thetobacco-entangled fabric can be packaged in individual pieces of anyshape or size and contained, for example, in a generally cylindricalcontainer 52 with a lid 54 (FIG. 1). Alternatively, as shown in FIG.16A, the melt-blown tobacco-entangled fabric can be packaged in a systemincluding a tray container 252 with a peel-away lid 254. The traycontainer 252 can include a plurality of isolated interior spaces 253A-Cso as to store separate stacks of the tobacco-entangled fabric 255. Thetobacco-entangled fabric in the stacks can be folded upon itself. Insome circumstances, the peel-away lid 254 can be resealable in that itcan be repeatedly secured to the container 252.

In another alternative system 260 depicted in FIG. 16B,tobacco-entangled fabric can be cut into a strip of a particular widthand packaged as a coil (e.g., rolled upon itself). As such, an adulttobacco consumer can readily tear or break away any length of the coilof tobacco-entangled fabric 265 for use in the mouth. In some cases, thecoil of tobacco-entangled fabric 265 can include perforations or scoresthat permit the adult tobacco consumer to more easily separate selectedlengths of the coil 265. The coil of tobacco-entangled fabric can becontained in a container 262 having a cylindrical interior space 253that is sized to receive the coil 265. In yet another alternative system270 depicted in FIG. 16C, the coil of tobacco-entangled fabric 275 canbe packaged in a container 272 that has a clipping device 273 on theside. The coil 275 can be stored in the container 272 having a lidthereon 274 (which may be removable), and the clipping device 273 can behingedly connected to a sidewall of the container 272 so that a selectedlength of the coil 275 can be drawn out and readily clipped away. Assuch, the adult tobacco consumer can select the particular size ofmelt-blown smokeless tobacco article to be inserted into the mouth.

In accordance with some embodiments and examples described herein, theremay be employed some conventional techniques within the skill of theart. Such techniques are explained fully in the literature. Someembodiments will be further described in the following examples, whichdo not limit the scope of the methods and compositions of matterdescribed in the claims.

EXAMPLE

A needled tobacco-entangled fabric was made as diagrammed in FIG. 17. Anapproximate 0.75 inch-thick layer of SKOAL Long Cut smokeless tobacco(Wintergreen flavored) having a moisture (i.e. oven volatiles) contentof 57% was placed on a spun laced cotton nonwoven web having a basisweight of 30 grams per square meter (gsm); the tobacco layer was thencovered with another layer of spun laced cotton nonwoven having a basisweight of 115 gsm. Another approximate 0.75 inch-thick layer of SKOALLong Cut smokeless tobacco (Wintergreen flavored) was placed on top ofthe 115 gsm layer and another layer of spun laced cotton nonwoven havinga basis weight of 30 gsm was placed on top of the second layer oftobacco. The layered composition was passed through the loom, turnedover, and passed through the loom again. Star blade needles were used at400 ppsi (penetrations per square inch) at a penetration depth of 7 mm.The loom was a Hunter Fiber-Locker loom set to have a feed rate of 41inches/minute, a rocker position of 0.25 and a penetration rate of 1405ppsi. The loom carriage position for a 5/16 penetration was set at 2 and56/64 inch. The loom gap penetration setting was set at 48/64 inch for afirst pass and at 32/64 inch for a second pass. The appearance andintegrity of the final product was excellent. The final product was easyto cut into squares and the tobacco remained in place. The spun lacedcotton nonwoven webs were obtained from Winner Medical Group, Inc.,Guangdong, China.

Other Embodiments

It is to be understood that, while the invention has been describedherein in conjunction with a number of different aspects, the foregoingdescription of the various aspects is intended to illustrate and notlimit the scope of the invention, which is defined by the scope of theappended claims. Other aspects, advantages, and modifications are withinthe scope of the following claims.

Disclosed are methods and compositions that can be used for, can be usedin conjunction with, can be used in preparation for, or are products ofthe disclosed methods and compositions. These and other materials aredisclosed herein, and it is understood that combinations, subsets,interactions, groups, etc. of these methods and compositions aredisclosed. That is, while specific reference to each various individualand collective combinations and permutations of these compositions andmethods may not be explicitly disclosed, each is specificallycontemplated and described herein. For example, if a particularcomposition of matter or a particular method is disclosed and discussedand a number of compositions or methods are discussed, each and everycombination and permutation of the compositions and the methods arespecifically contemplated unless specifically indicated to the contrary.Likewise, any subset or combination of these is also specificallycontemplated and disclosed.

1. (canceled)
 2. A non-tobacco product comprising, a non-tobaccomaterial having fibrous structures and a total oven volatiles content ofabout 20% by weight or greater; and two layers of melt-blownpolyurethane structural fibers positioned on opposite sides of thenon-tobacco material such that one layer of the melt-blown polyurethanestructural fibers is positioned on each of the opposite sides, themelt-blown polyurethane structural fibers having a diameter of 100microns or less.
 3. The non-tobacco product of claim 2, wherein eachlayer of melt-blown polyurethane structural fibers comprises a basisweight of about 30 grams per square meter (gsm).
 4. The non-tobaccoproduct of claim 2, wherein the non-tobacco material comprises a herbalcomposition.
 5. The non-tobacco product of claim 2, wherein the herbalcomposition comprises a culinary herb, thyme, lavender, rosemary,coriander, dill, mint, peppermint, a medicinal herbs, dahlia, cinchona,foxglove, meadowsweet, Echinacea, elderberry, willow bark, orcombinations thereof.
 6. The non-tobacco product of claim 2, wherein thenon-tobacco material is selected from the group consisting of tealeaves, red clover, coconut flakes, mint leaves, ginseng, apple, cornsilk, grape leaf, basil leaf, and combinations thereof.